Invisible edge solid substrate compensation layer for automotive glazing
Vehicle glazing, which once served just to provide for vision and protect from the elements, has been taking on new functions as the complexity and functionality of modern automobiles has evolved. Performance films and interlayers are often used to add to and enhance the functionality of laminates. These functions include solar control, sound dampening, head up display and variable light transmittance. Recent advances have made it possible to produce electronic circuits on thin transparent substrates that are essentially invisible under normal lighting conditions. While these circuits can be inserted into the laminate and successfully laminated, the edges of the circuit insert are prone to objectionable aesthetics due to mismatch between the substrate and the interlayer index of refraction, thickness and color. The present invention compensates the edge of the solid insert by providing a sheet of a compatible compensation material that the substrate of the insert and which extends to at least the black band or the edge of glass of the laminate making the insert edge essentially invisible.
1. An automotive laminate, comprising:
an outer glass layer;
an inner glass layer;
two plastic interlayers located between the outer and inner glass layers;
a single compensation layer consisting of a rigid transparent material made of glass or plastic, the compensation layer having a cutout area in a visible area of the laminate; and
an insert comprising a substrate made of a compatible material that is similar to or the same as the material of the compensation layer, such that the substrate and compensation layer match in at least one of index of refraction, color, and thickness, and active or passive electronics;
wherein the insert is placed into the cutout area in the single compensation layer;
wherein the single compensation layer and the insert are sandwiched between the two plastic interlayers and the single compensation layer is in contact with the two plastic interlayers; and;
wherein the single compensation layer has a glass transition temperature above an autoclave process temperature, wherein the autoclave process melts the two plastic interlayers.
2. The automotive laminate of claim 1 , wherein the glass transition temperature of the compensation layer is above about 100° C.
3. The automotive laminate of claim 2 , wherein the glass transition temperature of the compensation layer is above about 130° C.
4. The automotive laminate of claim 1 , wherein the rigid transparent material is plastic.
5. The automotive laminate of claim 4 , wherein the plastic material is polycarbonate.
6. The automotive laminate of claim 1 , wherein the compatible material of the substrate is glass or plastic.
7. The automotive laminate of claim 6 , wherein the rigid transparent material and the compatible material are the same material.
8. The automotive laminate of claim 1 , wherein the compensation layer and the substrate match in at least two of index of refraction, thickness and color.
9. The automotive laminate of claim 1 , wherein the active or passive electronics of the insert is selected from the group consisting of touch sensitive circuits, sensors, resistive heated circuits, rain sensors, OLED displays, LED displays and electroluminescent displays.
10. The automotive laminate of claim 1 , wherein a gap is formed between the insert and the compensation layer, said gap being filled with a resin.
11. The automotive laminate of claim 10 , wherein the gap is less than 0.5 mm.
12. The automotive laminate of claim 10 , wherein the resin is a UV cure laminating resin.
13. The automotive laminate of claim 1 , further comprising a black obscuration band.
14. The automotive laminate of claim 13 , wherein the edges of the compensation layer are hidden inside of the black obscuration band.
15. The automotive laminate of claim 1 , wherein the compensation layer is cold bent.
16. The automotive laminate of claim 1 , further comprising an infra-red reflecting coating.
17. A windshield comprising the automotive laminate of claim 1 .